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Ford Expedition Electrical Problems



  • Hey dale77, I'm not sure if you still have your Expedition, but I did find out what was causing the problem. I took it to Ford and found out it was the instrument cluster. The instrument cluster basically controls almost everything. They do have to find one with your same mileage on your truck and they have to re program all of your keys to the new cluster. I did look around to search for it a little cheaper, but the only problem was the shops I went to don't have the equipment to program the keys only Ford does. It ran a little over seven hundred and it depends on the mileage on the cluster. Thanks for your help
  • dale77dale77 Posts: 16
    Hello ednatheexpe:

    Thanks for the note. I was able to isolate the problem to the circuit board behind the instrument panel. See my post #201 with a link to detailed instructions with photos for the fix. By re-soldering the connector pins on the board, all of the problems went away. And it only cost me a couple of hours. The first time, I only re-soldered three of the pins but some of the problems re-surfaced. I repeated the process and this time made sure that the solder on all 9 pins melted and I added a small amount of new solder to each pin.
    In addition, I examined the entire back of the circuit board with a magnifying glass and found several other sloppy solders with thin threads of solder bridging circuit board conductors. These could easily cause a short and the type of symptoms I observed. The circuit board also had gobs of rosin around many of the solders. This rosin should have been cleaned with a solvent when the circuit board was manufactured. Old rosin can collect dust and moisture and cause problems. I carefully removed the rosin with an Exacto knife and then cleaned the affected areas with dry-cleaning fluid and a Q-Tip.

    I have not experienced problems since.

    While I had the instrument panel out of the dash, I also looked for evidence of water leaking in around the windshield because others on this site suggested that this could be a problem. I'm on my 4th windshield on this vehicle and found no evidence of moisture or corrosion anywhere behind or beneath the dash. So this does not seem to be relevant in my case.

    If one circuit board has the number of bad/sloppy solders, it suggests bad quality control and it is likely that others have the same problem.

    My fix is consistent with your remedy (replacing the unit) only it does not cost anything. I am convinced that many of the electrical problems reported on this site can be traced to bad/sloppy solders on the instrument panel circuit board.
  • I own a 07 Frod Expedition. Purchased brand new. My problem started the first year, my battery keeps going dead. A new battery only last 6 months to a year. I have went to the dealership for them to check out over and over, they put in on the computer and checked it out, everything is fine. it's the battery. WOW you can't make me believe it's the battery over and over again. Has anyone had this same problem with their battery going dead? If, you have and know what's the problem please I am asking please let me know. Thanks. I am at the end of my rope with my suv. starting to think it is trash.
  • Hi. I do too live in Miami and I would greatly appreciate it if you could share that mechanic's # with me. I have an electrical problem with my expo 2002. I had some sucker install tints on my windshield, and it seems that he dumped a lot of water on my dashboard, so it started messing with the dash lights, they would stay on after car had been turned off and key had been removed. After succesfully paying $300 to a [non-permissible content removed] shop, now my car has no power unless i start it, meaning no interior lights, no radio, no dash lights, and the trip odometer and radio reset everytime i turn off the car. I believe my problem will be the GEM most likely, but I cant afford to take it to the dealer. So any help will be greatly appreciated. My e-mail is
  • dale77dale77 Posts: 16
    I have posted messages #197, 201 and 213 describing dashboard electrical problems and the solution that worked for me. There is also a description with photos of the circuit board that is very helpful at the following link:">link title

    link title

    Since re-soldering all nine of the connector pins on the circuit board and cleaning the sloppy solders and rosin from the back of the board, I have driven 1000+miles with no problems whatsoever. This has clearly solved the problem.
  • jdj5166jdj5166 Posts: 2
    Hi I have a 01 Ford expedition and like everyone else I am having the same leak problems. I am a 29 year old woman who is pretty handy when told exactly what to do. I need to know 1. Is it possible to remove the luggage rack without cutting my head liner, and how do i go about sealing it up? 2. i removed the assist handle and would like to know how to go about sealing that also. 3 I would like to know how to seal the cowl. And my last question is what is the best thing to use to seal these areas. Thank you in advance.
  • I'd say the windshield is probably the most likely culprit of the things you've mentioned. Sealing the assist handle does nothing for you - it is not an entry point of water into the vehicle, it is an exit for water already in the a-pillar. By sealing it all you do is prevent the water from entering the cabin at that point, it will just go lower. Take it to a glass shop and have them check the seal on the windshield. With a compressor you can also do it yourself, although not as well as a shop. Do you have a sunroof? If you do you should check that the drains are running free.
  • jdj5166jdj5166 Posts: 2
    I have already had the windshield resealed. There is water that comes into the vehicle thru the assists handle. I do not have a sunroof. But the luggage rack seems to be a common culprit for water leaks and would really like to get that sealed up if I am able to find the easiest way of removing it. I see bolts on top but i am not sure if i have to go thru the headliner to additional hidden bolts.
  • alwaysfords2alwaysfords2 Posts: 288
    edited April 2011
    Probably the easiest way to handle the roof rack is to take one screw out at a time, put teflon tape on it and reinstall it. Give it a while and see what happens. You should check the drains at the cowl to make sure that water that rolls down the windshield drains right away and doesn't build up. Try it with a garden hose and the hood open. Again the water coming in through the handle is a symptom, not a cause so sealing it really doesn't help you much.
  • remixthisremixthis Posts: 1
    Please help! I have a '97 Eddie Bauer Expediiton that I bought used a few months ago. Last week one night when I got in the vehicle after work the interior lights were flashing on and off as soon as I opened the door. When I closed the door they stopped, I started the truck and was on my way.
    2 days later the problem was still happening, only now the door locks and windows stopped working. They make a sound like they want to work, but no dice. The door locks actually sound like they're straining to open for some reason, and the windows just make a noise. The radio and heat and a/c work fine. Does anyone have any ideas that can help me? Could this be connected to the anti-theft system at all?? Thanks!!!
  • need_some_helpneed_some_help Posts: 2
    edited May 2011
    Did you ever figure the problem out (#214)? I am having a similar issue with my 2003 Expy. Battery went dead would jump instantly but keeps going dead. I have a short in my fuse panel somewhere. Pulling the fuses didn't solve it but figured out which wire it is, wire that sends power to the on-demand dome lights, not the automatic interior lights which should be circuit #24 which also powers the Battery Saver Relay so I'm thinking that may be the problem but I have no idea how to test the relays that are molded to the control board or where I can buy just the control board. Any help will be greatly appreciated.

  • kd4kmzkd4kmz Posts: 19
    Rear Wiper assembly stuck has normally caused this issue
  • kd4kmzkd4kmz Posts: 19
    Yes I did, but the 2001 and 2003 are different issues, the 2001 is an issue with water getting into the GEM. The 2003 is an issue with solder issues in the instrument, you either search and solder everything or you replace it, I had solder everything and it went away for a while then came back, after finally replacing it, all my electrical issues went away, they are passing the voltage through the instrument panel and not through direct harnes to get to rdio and windows, pretty stupid I know but there you go
  • Did you replace the instrument panel in the dash or the CJB control board in the kick panel? After doing some research today I see the wire I referenced looks as though it goes to an interior lamp relay that appears to be part of the instrument cluster/panel. Can you confirm? I reinstalled the CJB today and I'm getting a slight arch when I connect the positive battery cable. It started, ran to pick the boy up, started there and then back home. Now it won't start, lots of clicking in the CJB, hope I didn't mess that up but its raining now and to far to push to the garage. Any ideas about the sparking or the no start now after it worked fine twice?
  • tpiercetpierce Posts: 1
    I have a 1999 Expedition. The battery continues to drain as locks on door are up and down clicking. One time I was driving in the rain and the radio would come on when I used the turn signal. I have brought into Ford 3 times they supposely replaced windshield and seal, replace computer (main) under the hood. I don't know what to do. I don't want to bring back to Ford. This happens every time it rains. Please I need some possible solutions.
  • eddie2004eddie2004 Posts: 1
    my 2004 expedition climate control panel no display or controls. I replaced 10 amp fuse and it worked briefly. I rechecked fuse and it's good still no heat or ac. panel is still dead. Alternator replaced a few days afterward not sure if it is related. still no heat or ac. Not sure where to start looking?
  • ridiculous_1ridiculous_1 Posts: 2
    edited July 2011
    I have an 05 King Ranch and I replaced my battery and ever since the DVD player will play video but no sound. The wireless headphones will only play the radio even when the DVD is playing....Any ideas or suggestions?

    Is this electrical in nature..did I short something..or just a setting I need to re-enable.
  • berggyberggy Posts: 2
    There is water in your relay box just above and left of the steering column.
    It comes from the leaking windshield.
    Look up my photo series and fix on the ford truck enthusiasts web site under electrical insanity.

    Oh wait ... I found it:
  • berggyberggy Posts: 2
    try this:
    There is water in your relay box just above and left of the steering column.
    It comes from the leaking windshield.
    Look up my photo series and fix on the ford truck enthusiasts web site under electrical insanity.

    Oh wait ... I found it:
  • i have a 99 EB Expedition. when i shut the car off, take keys out, and open doors, the door dinger still dings, the windows still work, and the a/c still blows. sometimes while im driving the radio will go off and the mileage wont work. i can drive it all day with no problems. but if i let it sit a couple days the battery ends up dying. the other day(it was raining) i heard a clicking noise coming from under the dashboard. i could not isolate exactly where it was coming from. i checked all relays under the dash, and they are all good. also if i hit the brakes really hard, the abs light will come on and stay on until i shut truck off. ive read a lot about this on the forums, but no one has the exact same problems as me. any help is appreciated!
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